Envelope film suspenders for high-altitude balloons

ABSTRACT

A high altitude or stratospheric balloon system may include a balloon envelope including envelope film, at least one tendon, and a suspender. The suspender may have a first end attached to the envelope film. The suspender is arranged to stretch such that the first end moves towards an equator of the balloon envelope as the balloon envelope pressurizes in order to control movement of the envelope film relative to the tendon and towards the equator as the balloon pressurizes.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.15/801,648, filed on Nov. 2, 2017, the disclosure of which isincorporated herein by reference.

BACKGROUND

Computing devices such as personal computers, laptop computers, tabletcomputers, cellular phones, and countless types of Internet-capabledevices are increasingly prevalent in numerous aspects of modern life.As such, the demand for data connectivity via the Internet, cellulardata networks, and other such networks, is growing. However, there aremany areas of the world where data connectivity is still unavailable, orif available, is unreliable and/or costly. Accordingly, additionalnetwork infrastructure is desirable.

BRIEF SUMMARY

One aspect of the disclosure provides a system. The system includes aballoon envelope including envelope film, at least one tendon, and asuspender having a first end attached to the envelope film, thesuspender being configured to stretch such that the first end movestowards an equator of the balloon envelope as the balloon envelopepressurizes in order to control movement of the envelope film relativeto the tendon and towards the equator as the balloon pressurizes.

In one example, the first end is arranged to move away from an apex ofthe balloon envelope when the first end is moving towards the equator.In this example, the system also includes a second tendon and a secondsuspender having a first end attached to the envelope film, the secondsuspender being configured to stretch such that the first end of thesecond suspender moves towards the equator of the balloon envelope asthe balloon envelope pressurizes in order to control movement of theenvelope film relative to the second tendon towards the equator as theballoon pressurizes. In addition, the first end of the second suspenderis arranged to move towards an apex of the balloon envelope when thefirst end of the second suspender is moving towards the equator. In thisexample, the system also includes a base plate system arranged at a baseof the balloon envelope, and wherein a second end of the secondsuspender is attached to the base plate system. Further, the base platesystem includes a mounting point, and wherein the second end of thesecond suspender is attached to the mounting point. In addition, thebase plate system includes a mounting point, and wherein the second endof the second suspender is configured to loop around the mounting point.In addition or alternatively, the mounting point is a stud, and inaddition, the second tendon is attached to the stud.

In another example, at least one point on the tendon is fixed relativeto the envelope film. In this example, the at least one point isproximate to a midpoint of the tendon. In another example, the envelopefilm includes a sleeve arranged over the tendon, and wherein the firstend is attached to the sleeve. In another example, the system alsoincludes a top plate system, and wherein a second end of the suspenderis attached to the top plate system. In this example, the top platesystem includes a mounting point, and wherein the second end of thesuspender is configured to loop around the mounting point. In addition,the mounting point is a stud, and in this example, the tendon isattached to the stud. In addition or alternatively, the suspender isconfigured to hold a gathered portion of the envelope film towards thetop plate system and away from the equator prior to pressurization. Inthis example, the suspender is configured to allow the gathered portionof the balloon envelope film to move towards the equator duringpressurization. In another example, the balloon envelope includes aplurality of gores and a doubler film attached to the plurality ofgores, and wherein a second end of the suspender is attached to thedoubler film. In another example, the balloon envelope includes aplurality of gores and a doubler film attached to the plurality ofgores, and wherein the suspender is an extension from the doubler film.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a functional diagram of a network in accordance with toaspects of the disclosure.

FIG. 2 is an example of a balloon in accordance with aspects of thedisclosure.

FIG. 3 is an example of a balloon in accordance with aspects of thedisclosure.

FIGS. 4A-4B are example representations of a top plate system and baseplate system with a tendon attached to envelope film at a series of tackpoints in accordance with aspects of the disclosure.

FIGS. 5A-5B are example representations of a top plate system and baseplate system with a tendon attached to envelope film and a pair ofleashes in accordance with aspects of the disclosure.

FIG. 6 is an example representation of a top plate system and base platesystem with a tendon attached to envelope film and a pair of leashes fora pressurized balloon envelope in accordance with aspects of thedisclosure.

FIGS. 7A-7B are example representations of a top plate system and baseplate system with a tendon and a pair of suspenders in accordance withaspects of the disclosure.

FIGS. 8A-8C are example suspenders in accordance with aspects of thedisclosure.

FIG. 9 is an example representation of a top plate system and base platesystem with a tendon and a pair of suspenders for a pressurized balloonenvelope in accordance with aspects of the disclosure.

FIG. 10 is an example balloon envelope, top plate system and base platesystem in accordance with aspects of the disclosure.

FIG. 11 is an example doubler film with suspenders in accordance withaspects of the disclosure.

FIG. 12 is an example flow diagram in accordance with aspects of thedisclosure.

DETAILED DESCRIPTION

Overview

The technology relates to controlling the movement of balloon envelopefilm over tendons during pressurization of a stratospheric orhigh-altitude balloon. The tendons may be arranged within a tubing or atubular sleeve of the same or similar material as the balloon envelope.Each end of each tendon is connected to a top plate and base platearranged at the apex and base of the balloon envelope, respectively. Thetendons thus provide support for the balloon envelope.

As balloon rises towards the stratosphere, the drop in temperature ofaround 80 degrees Celsius causes the envelope film to shrink, forinstance around 1.5% or 150-180 ppm or more or less. However, thetendons do not have the same thermal rate of expansion, and in fact maynot change much at all or even expand slightly due to stresses on thetendons. Because of this, the length of the envelope film between thetop plate and base plate must be greater than the length of the tendonswhen the balloon is at ground level, for instance, at 20 degrees C. Asthe balloon envelope pressurizes and expands, the envelope film willmove along the tendons, but the envelope film has a tendency todistribute itself unevenly causing unwanted strain at different pointsalong the tendons.

To address this problem, tack points may be used to hold the envelopefilm to the tendons at several locations along each tendon. While thiscan provide adequate distribution of the envelope film along thetendons, it may be a painstaking and incredibly time consuming process.

As an alternative, breakaway tack points may be used. These tack pointsmay be strong enough to handle launch at warm temperatures, but maybreak at very low pressure in the balloon, allowing the film to movedownwards immediately prior to pressurization. However, the tack pointsmay not all fail evenly and the film movements could be rather sudden.

As an alternative to using multiple tack points for each tendon, anotherapproach may be to use a tether or leash. During pressurization, theenvelope film may be pulled towards the equator of the balloon envelopeand the force on the leash causes the leash to break. Again, because theenvelope film tends to be pulled towards the equator duringpressurization, the envelope film is more likely to be distributedevenly along the tendon. However, the leashes may have a tendency tobreak at different times which can create unwanted stress on theenvelope film. To address this concern, the leashes may be made longenough to avoid having them break.

To avoid the difficulties in attaching the tack points and leashes aswell as in having all of the breakable leashes and tack points for eachtendon break at the same time in the same way, suspenders may be used.Each suspender may be attached to a stud of the top plate system or baseplate system and to the balloon envelope either at the tubular sleeve ofone of the tendons or the center of one of the gores. As an alternative,the suspenders may be attached to a doubler film near the apex of theballoon envelope.

Each suspender may be a single strap folded back on itself to form aloop of material configured to stretch, rather than break, as theenvelope material is pulled towards the equator during pressurization.By using a loop, the suspender can be sealed to the tubular sleeve andlooped around the stud making attachment much simpler than that of aleash or tack point discussed above. Alternatively, each suspender maybe a single strap that is heat sealed to the envelope material at oneend, and secured to a stud via an eye in the suspender.

The suspenders may be made of the same or similar materials as thematerial of the envelope film or any other low temperature, ductileviscoelastic materials. The geometry of the suspenders may be variedaccording to the amount of stretch required for the application.

The features described herein may allow for the controlled movement ofballoon envelope film during pressurization of a stratospheric orhigh-altitude balloon. In addition, by using a loops of film materialwith a single tack point at or proximate to the equator, manufacture isgreatly simplified as compared to the time consuming process of usingmultiple tack points. Moreover, using a suspender which stretches andgives avoids the unpredictable nature of the other approaches describedherein.

Example Balloon Network

FIG. 1 depicts an example network 100 in which a balloon as describedabove may be used. This example should not be considered as limiting thescope of the disclosure or usefulness of the features of the films andballoon envelopes as described herein. For example, the films may beemployed on various types of balloons, such as balloons carryingtelescopes, surveillance gear, weather sensors or other types ofstandalone balloons or balloons used with other types of systems. Inthis example, network 100 may be considered a “balloon network.” Theballoon network 100 includes a plurality of devices, such as balloons102A-F, ground base stations 106 and 112 and links 104, 108, 110 and 114that are used to facilitate intra-balloon communications as well ascommunications between the base stations and the balloons. One exampleof a balloon is discussed in greater detail below with reference to FIG.2.

Example Balloon

FIG. 2 is an example stratospheric balloon 200, which may represent anyof the balloons of balloon network 100. As shown, the balloon 200includes a balloon envelope 210, a payload 220 and a plurality oftendons 230, 240 and 250 attached to the balloon envelope 210. In thisexample, balloon envelope 210 may be inflated to a desired level, butnot yet pressurized.

The balloon envelope 210 may take various forms. In one instance, theballoon envelope 210 may be constructed from materials such aspolyethylene that do not hold much load while the balloon 200 isfloating in the air during flight. Further, the volume of the balloonenvelope may be on the order of 2000 cubic meters. However, the shapeand size of the balloon envelope 210 may vary depending upon theparticular implementation. Additionally, the balloon envelope 210 may befilled with various gases or mixtures thereof, such as helium, hydrogenor any other lighter-than-air gas. The balloon envelope 210 is thusarranged to have an associated upward buoyancy force during deploymentof the payload 220.

The payload 220 of balloon 200 is affixed to the envelope by aconnection 260 such as a cable. The payload 220 may include a computersystem (not shown), having one or more processors and on-board datastorage. The payload 220 may also include various other types ofequipment and systems (not shown) to provide a number of differentfunctions. For example, the payload 220 may include an opticalcommunication system, a navigation system, a positioning system, alighting system, an altitude control system and a power supply to supplypower to various components of balloon 200.

In view of the goal of making the balloon envelope 210 as lightweight aspossible, it may be comprised of a plurality of envelope lobes or goresthat have a thin film, such as polyethylene or polyethyleneterephthalate, which is lightweight, yet has suitable strengthproperties for use as a balloon envelope. In this example, balloonenvelope 210 is comprised of envelope gores 210A-210D. Although only afew gores are depicted in the example of balloon 200, a typical balloonmay include as many as 30, 48, 60 or more or less gores.

Pressurized lift gas within the balloon envelope 210 may cause a forceor load to be applied to the balloon 200. In that regard, the tendons230-250 provide strength to the balloon 200 to carrier the load createdby the pressurized gas within the balloon envelope 210. As shown moreclearly in FIG. 3, depicting the balloon envelope 210 as beingpressurized (i.e. in a nominal condition when floating in thestratosphere), the tendons are arranged along a centerline of each ofthe gores 210A-210B. Alternatively, the tendons may be arranged at theseams between the gores. In some examples, a cage of tendons (not shown)may be created using multiple tendons that are attached vertically andhorizontally. Each tendon may be formed as a fiber load tape that isadhered to a respective envelope gore. Alternately, a tubular sleeve maybe adhered to the respective envelopes with the tendon positioned withinthe tubular sleeve.

Top ends of the tendons 230, 240 and 250 may be coupled together using atype of plate, such as top plate system 201 positioned at the apex ofballoon envelope 210. Each tendon may also be positioned withinrespective tubular sleeves which may be made of the same or similarmaterial as the balloon envelope and attached to the balloon envelope byheat sealing to the midline of a gore or between two gores. Bottom endsof the tendons 230, 240 and 250 may also be connected to one another atbase plate system 202. For example, a corresponding plate, e.g., baseplate system 202, is disposed at a base or bottom of the balloonenvelope 210. The top plate system 201 at the apex may be the same sizeand shape as and base plate system 202 at the bottom. Both plate systemsinclude corresponding components for attaching the tendons 230, 240 and250. In some examples, the top plate system 201 may serve a mountingpoint for certain systems attached to the balloon 200.

FIG. 2 depicts the balloon envelope 210 inflated with lift gas close toground level, for instance, at atmospheric pressure. As the balloonrises and the atmospheric pressure drops, the lift gas within theballoon envelope expands, changing the shape of the balloon envelope.Eventually, for instance, when the balloon envelope reaches thestratosphere, the lift gas in the balloon envelope causes the balloonenvelope to form more of a rounded pumpkin shape depicted in FIG. 3.

In some examples, manufacturing of the balloon envelope involves heatsealing portions of the film material in order to produce the gores. Forinstance, portions of film material which will form the gores may belaid out on a table and then sealed together, for example, using a heatbond. This heat bond of the film material can be employed using varioustechniques.

As noted above, tack points to hold the envelope film to the tendons atseveral locations along each tendon. FIG. 4A is a representation of topplate system 201 and base plate system 202 with a tendon 230 attached toenvelope film 400 (of balloon envelope 210) via a series of 5 tackpoints 410, 412, 414, 416, 418. FIG. 4B is another representation of topplate system 201 and base plate system 202 with a tendon 230 attached toenvelope film 400 (of balloon envelope 210) via the series of 5 tackpoints 410, 412, 414, 416, 418. In the example of FIG. 4B, tubularsleeve 420 is visible. Each of the tack points 410, 412, 414, 416, 418may be evenly distributed along the tendon such that tack point 414 islocated proximate to an equator of the balloon envelope (see equatorline in FIG. 3). Although, only a single tendon is depicted for clarity,the balloon envelope may have 30, 48, 60 or more tendons, and eachtendon may be attached to a respective tubular sleeve via a series oftack points.

To make a tack point, an opening may be cut into the tubular sleeve, andtape may be applied over the opening to hold the tendon to the tendonand balloon envelope. In this regard, FIG. 4B depicts a series ofopenings 430, 432, 434, 436, 438 in tubular sleeve 420 proximate to eachtack point 410, 412, 414, 416, 418. In this regard, each tack point maycorrespond to a respective piece of tape and may have a respectivecorresponding opening.

In addition, between a pair of tack points or a tack point and a top orbase plate, the amount of envelope film and length of tendon must bemeasured to a high degree of accuracy in order to distribute theenvelope film as evenly as possible along the tendons when the balloonenvelope is pressurized. While this may provide adequate distribution ofthe envelope film along the tendons, it may be a painstaking andincredibly time consuming process as some balloons may have 30, 48, 60or more tendons and each tendon may requires 5 to 13 or more tackpoints.

As an alternative, breakaway tack points may be used. This may includeusing small strips of material such as envelope film or other plasticthat are adhered around the tendon, for instance using tape or glue, andheat sealed to the tubular sleeve. This heat sealing may thus includemelting the strip of material into the tubular sleeve. For instance, asan alternative to tape, tack points 410, 412, 414, 416, 418 may eachcorrespond to a strip of material that is wrapped around tendon 230 andheat sealed to the tubular sleeve 420.

These breakaway tack points may be strong enough to handle launch atwarm temperatures, such as between 20 and 30 degrees Celsius, but maybreak at very low pressure in the balloon, allowing the film to movedownwards immediately prior to pressurization. These tack points maykeep the material from slumping away from the apex due to gravity andcausing the meridional or machine direction of the balloon envelope(“MD”) load to be high at the plate, a known failure mode of balloonswith uncontrolled film (i.e. film that does not move smoothly over thetendons during pressurization. However, the tack points may not all failevenly and the film movements could be rather sudden.

As an alternative to using multiple tack points for each tendon, anotherapproach may be to use pairs of tethers or leashes for each tendon. FIG.5A is a representation of top plate system 201 and base plate system 202with a tendon 230 attached to envelope film 500 (of balloon envelope210) via a tack point 510 as well as a pair of leashes 520, 522. FIG. 5Bis another representation of top plate system 201 and base plate system202 with a tendon 230 attached to envelope film 500 (of balloon envelope210) via a tack point 510 as well as the pair of leashes 520, 522. Inthe example of FIG. 5B, tubular sleeve 530 and openings 540, 542, 544are visible. As in the examples above, although, only a single tendon isdepicted for clarity, the balloon envelope may have 30, 48, 60 or moretendons, and each tendon may be attached to a respective tubular sleevevia a pair of leashes similar to leashes 520, 522.

In this example, a single tack point may be placed at the longitudinalcenter or midpoint of the tendon and longitudinal center or midpoint ofthe envelope film (i.e. the equator). For instance, tack point 510 isproximate to or at the equator of the balloon envelope and the middle oftendon 230. The envelope film is then bunched towards the top platesystem 201 and also towards the base plate system 202, or in otherwords, away from the equator. Thereafter, two leashes may be attached tothe balloon envelope and the tendon by cutting open the tubing andsealing or taping one end of the leash to the inside of the tubing andanother end of the leash to the tendon. Alternatively, the leash may beattached to the envelope film or tubular sleeve for instance, via heatsealing, taping, or gluing, without cutting.

As can be seen from FIGS. 5A and 5B, leashes 520, 522 are locatedproximate to the top plate system 201 and base plate system 202,respectively. Leash 520 holds a portion 501 of gathered envelope film500 towards the top plate system 201 via a heat sealed attachment point550 on the tubular sleeve 530 and tape 560 on the tendon 230. Leash 522holds a portion 502 of gathered envelope film 500 towards the base platesystem 202 via a heat sealed attachment point 552 on the tubular sleeve530 and tape 562 on the tendon 230. Alternatively, one or both ofattachment points 550, 552 may be located on a different portion of theenvelope film, such as some point on one of the gores.

During pressurization, the envelope film may be pulled towards theequator and the force on the leash causes the leash to break. Forinstance, turning to FIG. 6, the portions 501, 502 are pulled towardsthe equator in the directions of arrows 610 and 612, respectively, andare indistinguishable from the rest of the envelope film 500. Again,because the envelope film tends to be pulled towards the equator of theballoon during pressurization, the envelope film is more likely to bedistributed evenly along the tendon 230. For instance, FIG. 6 depictsthe example of FIGS. 5A and 5B where envelope film 500 is pressurized.Both leashes 520 and 522 have broken into leash portions 520A, 520B and522A, 522B, respectively. As can be seen leash portion 520A remainsattached to tendon 230, and leash portion 520B, 522B remain attached tothe envelope film 500 (or more particularly, to the tubular sleeve 530,not shown).

Ideally, all of the leashes proximate to the top plate system will breakclose to or at the same time while all of the leashes proximate to thebase plate system will break close to or at the same time. However, thistiming is difficult to control, and thus, the leashes may have atendency to break at different times which, in turn, can cause the filmat two adjacent tendons to move towards the equator at different timescreating diagonal folds in the envelope film which can create unwantedstress risers. To address this concern, the leashes may be made longenough to allow the leashes to stretch and avoid having the leashesbreak. For instance, the amount of stretch required may be as little as30% of the total length of the leashes, while shorter leashes with morestretch may be preferred from a film control perspective, with as muchas 200% elongation in the design theoretically being achievable.

To avoid the difficulties in attaching the tack points and leashes aswell as in having all of the breakable leashes and tack points for eachtendon break at the same time in the same way, pairs of suspenders maybe used. FIG. 7A is a representation of top plate system 201 and baseplate system 202 with a tendon 230 attached to envelope film 700 (ofballoon envelope 210) via a tack point 710 as well as a pair ofsuspenders 720, 722. FIG. 7B is another representation of top platesystem 201 and base plate system 202 with a tendon 230 attached toenvelope film 700 (of balloon envelope 210) via a tack point 710 as wellas the pair of suspenders 720, 722. In the example of FIG. 7B, tubularsleeve 730 and opening 732 is visible. As in the examples above,although, only a single tendon is depicted for clarity, the balloonenvelope may have 30, 48, 60 or more tendons.

Each suspender may be attached at one end to a mounting point of theplate system or base plate system. For instance, a first end 750 ofsuspender 720 may be attached to mounting point 740 of top plate system201, while a first end 752 of suspender 722 may be attached to mountingpoint 742 of base plate system 202. For the suspenders attached to thetop plate system, each suspender may share a mounting point with one ormore other suspenders or may alternatively have its own respectivemounting point. Similarly, for the suspenders attached to the base platesystem, each suspender may share a mounting point with one or more othersuspenders or may alternatively have its own respective mounting point.In this regard, one or more additional suspenders attached to othertendons of the balloon envelope may also be attached to the mountingpoint 740 and/or 742.

In one example, the mounting point may be a stud used to attach thetendons to the top plate system or base plate system. In this regard,the stud may be shaped to allow a tendon to be looped around orotherwise attached to the stud with a clamp, bracket, or other device.For instance, mounting points 740 and/or 742 may each be a stud asdepicted in FIGS. 7A and 7B, only a single stud being depicted forclarity. As each tendon has its own respective stud on each of the topplate system and base plate system. If there is a suspender for eachgores and/or tendons of the balloon envelope, in this example, eachsuspender may have it's own respective stud. Alternatively, two or moresuspenders may be attached to a given stud.

Another end of each suspender may be attached to the envelope filmeither at the tubing of one of the tendons or the center of one of thegores. For instance, a second end 760, opposite of first end 750, ofsuspender 720 may be attached to the envelope film 700. Similarly asecond end 762, opposite of first end 752, of suspender 720 may beattached to a portion 762 of the envelope film 700.

Each suspender may be a single strap folded back and heat sealed toitself to form a loop of material configured to stretch, rather thanbreak, as the envelope material is pulled towards the equator and awayfrom the apex or base during pressurization. For instance, FIG. 8Adepicts a suspender 800A which may correspond to suspender 720 or 722.Suspender 800A is configured as a loop having a first end 850A, whichmay correspond to first ends 750 and/or 752, and an opposite second end860B, which may correspond to second end 760 and/or 762. In thisexample, suspender 800A may be formed as a loop by heat sealing a stripof material into the loop at point 810A. By using a loop, the suspendercan be sealed to the tubing and easily looped around the stud makingattachment much simpler than that of a leash or tack point discussedabove.

Alternatively, each suspender may be a single strap that is heat sealedto the envelope material at one end, and secured to a stud via an eye orloop in the suspender. FIG. 8B depicts a suspender 800B which maycorrespond to suspender 720 or 722. Suspender 800B is configured as aloop having a first end 850B, which may correspond to first ends 750and/or 752, and an opposite second end 860B, which may correspond tosecond end 760 and/or 762. In this example, suspender 800B may beinclude an eye 810B formed by cutting or punching out the eye at thefirst end 850B. FIG. 8C depicts a suspender 800C which may correspond tosuspender 720 or 722. Suspender 800C is configured as a strip with aloop at first end 850C, which may correspond to first ends 750 and/or752, and an opposite second end 860C, which may correspond to second end760 and/or 762. In this example, the loop may be formed by heat sealingthe strip of material to itself at point 810C.

The suspenders may be made polyethylene film which is the same as orsimilar to that of the material of the envelope film. Alternatively, thesuspenders may be made of any other low temperature, ductileviscoelastic material, including urethanes, other olefins, siliconecompounds, etc.

Returning to the examples of FIGS. 7A and 7B, suspenders 720, 722 arelocated proximate to the top plate system 201 and base plate system 202,respectively. Suspender 720 holds a portion 701 of gathered envelopefilm 700 towards the top plate system 201 and away from the equator viathe first end 750 at the mounting point 740 and second end 760 which maybe heat sealed to the envelope film 700, for instance in the middle of agore or on a tubular sleeve of a tendon. Suspender 722 holds a portion702 of gathered envelope film 700 towards the base plate system 202 andaway from the equator via the first end 752 at the mounting point 742and second end 762 which may be heat sealed to the envelope film 700,for instance in the middle of a gore or on a tubular sleeve of a tendon.

During pressurization, the envelope film may be pulled towards theequator. The force on the suspenders may cause the suspenders to stretchtowards the equator rather than break. When fully pressurized, thesuspenders may lie flat against the envelope film. For instance, turningto FIG. 9, the portions 701, 702 are pulled relative to and along thetendon 230 towards the equator in the directions of arrows 910 and 912,respectively, and are indistinguishable from the rest of the envelopefilm 700. At the same time, the second ends 760, 762 are pulled towardsthe equator and away from the apex and base, respectively. At the sametime, second ends 760, 762 are pulled towards the base and apex,respectively.

Again, because the envelope film tends to be pulled towards the equatorof the balloon during pressurization, the envelope film is more likelyto be distributed evenly along the tendon 230. For instance, FIG. 9depicts the example of FIGS. 7A and 7B where envelope film 700 ispressurized. Both suspenders 720 and 722 have stretched towards theequator may lie flat against the envelope film 700. As can be seen firstends 750, 752 remain attached to the top plate system 201 and base platesystem 202, respectively, and second ends 760, 762 remain attached tothe base plate system, respectively.

The geometry of the suspenders may be varied according to the amount ofstretch required for the application. For instance, a suspender may be astrip of film approximately 1 meter long or more or less, 1-2 mil thickor more or less, and 1 inch wide or more or less. In addition, theconfiguration of the suspenders may or may not be symmetrical, orrather, the same at the top plate system and the base plate system.Although the examples above refer to straps or loops, the suspenders maytake a variety of different shapes including straight, curved, or flaredto properly and consistently distribute the load between the twoendpoints.

As an alternative to the mounting point examples, the first ends of thesuspenders may be attached to a doubler film arranged near the apex orbase of the balloon envelope. For instance, as shown in FIG. 10, doublerfilm 1010, 1020 may each be a circular piece of the envelope film usedto “cap” off the gores of the balloon envelope at the top and base ofthe gores. These doubler films may be heat sealed to the gores 210A,210B, 210C, 210D, etc. Thereafter, the top plate system 201 may beattached to the balloon envelope at the double film 1010, for instanceby heat sealing the doubler film and top plate system, and the baseplate system 202 may be attached to the balloon envelope at the doublefilm 1020, for instance by heat sealing the doubler film and top platesystem. In this example, rather than being attached to a mounting pointof the top plate system or base plate system, the second ends of thesuspenders may be heat sealed to the envelope film. When the doublerfilm 1010 or 1020 is installed, a heat seal may be executed between thegores, the first ends of the suspenders, and the doubler film 1010 or1020. Thereafter, each of the top plate system 201 and base plate system202 may be heat sealed to the envelope film at the double films 1010,1020, respectively.

In another instance, the doubler film may be pre-built with suspenderssealed onto the doubler film or cut into the doubler film as a singlecomplex shape. FIG. 11 is an example double film 1110 with a pluralityof suspenders 1120A-1120H. Although only 6 suspenders are depicted forclarity, the number of suspenders may be equal to or less than thenumber of gores of the balloon envelope. The first ends 1130A-1130H ofthese suspenders may be attached to the double film 1110 via a heatseal. Alternatively, these first ends may be incorporated into thedouble film 1110, for instance, being cut into the shape depicted inFIG. 11 from a large piece of film material. The second ends1140A-1140AH each extend away or are extensions from the doubler film1110. The doubler film is then attached to the gores with no extra filmin the balloon envelope, and thereafter the suspenders may be attachedto the envelope film as discussed above.

FIG. 12 is an example flow diagram 1200 for an example assembly and useof the suspenders. In this example, at block 1202 during manufacture ofthe balloon envelope, a second end of a suspender is heat sealed to theenvelope film, for instance in the center of a gore or on a tubularsleeve of a tendon. This may be repeated for the desired number oftendons for each of what will become the apex and the base of theballoon envelope. At block 1204, once the top plate system and baseplate system are heat sealed to the balloon envelope, a portion of theenvelope fill may be gathered towards the top plate system, and thefirst end of the suspender may be attached to a mounting point on thetop plate system. This may be repeated for the each of the remainingsuspenders for each of the top plate system and base plate system. Atblock 1206, the balloon envelope may be inflated, for instance using alift gas supply attached to a fill port of the top plate system, andlaunched, or rather released and allowed to float. At block 1208, afterlaunch, as the balloon envelope rises towards the stratosphere, theenvelope may begin to pressurize. At block 1210, during pressurization,the gathered portion of the envelope film may then be pulled towards anequator of the balloon envelope. At the same time, the suspendersstretch and the second ends of the suspenders are pulled towards theequator and pulled away from the first ends of the suspenders (either atthe top plate system or base plate system). At block 1212, once theballoon envelope is fully pressurized, the suspenders may remainstretched flat against the balloon envelope.

Most of the foregoing alternative examples are not mutually exclusive,but may be implemented in various combinations to achieve uniqueadvantages. As these and other variations and combinations of thefeatures discussed above can be utilized without departing from thesubject matter defined by the claims, the foregoing description of theembodiments should be taken by way of illustration rather than by way oflimitation of the subject matter defined by the claims. In addition, theprovision of the examples described herein, as well as clauses phrasedas “such as,” “including” and the like, should not be interpreted aslimiting the subject matter of the claims to the specific examples;rather, the examples are intended to illustrate only one of manypossible embodiments. Further, the same reference numbers in differentdrawings can identify the same or similar elements.

The invention claimed is:
 1. A method comprising: inflating a balloonenvelope of a balloon with lift gas, the balloon envelope including atleast one suspender arranged in order to gather a portion of envelopefilm adjacent to a plate system of the balloon envelope; allowing theballoon envelope to rise towards the stratosphere and pressurize; andduring the pressurization, pulling the gathered portion of envelope filmtowards an equator of the balloon envelope and allowing the suspender tostretch against the balloon envelope.
 2. The method of claim 1, whereinwhen the balloon is fully pressurized, the suspender is arranged flatagainst the balloon envelope.
 3. The method of claim 1, wherein theplate system is arranged at an apex of the balloon.
 4. The method ofclaim 1, wherein the plate system is arranged at a base of the balloon.5. The method of claim 1, wherein the suspender includes a first endattached to a mounting point of the plate system and a second endattached to the balloon envelope.
 6. The method of claim 5, wherein thesuspender shares the mounting point with at least one other suspenderarranged in order to gather a second portion of envelope film adjacentto the plate system, and wherein the method further comprises, duringthe pressurization, pulling the second gathered portion of envelope filmtowards an equator of the balloon envelope and allowing the at least oneother suspender to stretch against the balloon envelope.
 7. The methodof claim 5, further comprising, attaching the first end to the mountingpoint.
 8. The method of claim 5, wherein the mounting point is a studused to attach a tendon to the plate system, and wherein the methodfurther comprises attaching the first end to the stud.
 9. The method ofclaim 5, wherein the balloon envelope includes tubing for a supporttendon of the balloon, and the method further comprises attaching thesecond end to the tubing.
 10. The method of claim 9, wherein attachingthe second end to the tubing includes heat sealing the second end to thetubing.
 11. The method of claim 5, wherein the balloon envelope includesa plurality of gores, and the method further comprises attaching thesecond end to one of the plurality of gores.
 12. The method of claim 11,wherein attaching the second end to the one of the plurality of goresincludes heat sealing the second end to the one of the plurality ofgores.
 13. The method of claim 1, wherein the suspender includes a loopat a first end, and the method further comprises attaching the loop tothe plate system.
 14. The method of claim 13, further comprising,forming the loop by heat sealing a portion of the suspender to itself.15. The method of claim 13, wherein the suspender includes an eye at afirst end, and the method further comprises attaching the loop to theplate system.
 16. The method of claim 15, further comprising, formingthe eye by cutting or punching the suspender.
 17. The method of claim 1,wherein the stretching does not cause the suspender to break.
 18. Themethod of claim 1, wherein the suspender includes first and second ends,and during the pressurization, as the suspender stretches, the secondend of the suspender is pulled towards the equator.
 19. The method ofclaim 18, wherein during the pressurization, as the suspender stretches,the first end remains attached to the plate system.
 20. The method ofclaim 1, wherein the suspender includes a first end, the balloonincludes a piece of film arranged near an apex or a base of the balloonenvelope, the piece of film being attached to the plate system, and thesuspender further includes a second end attached to the balloonenvelope, and wherein the method further comprises, attaching the firstend to the piece of film.